®

TOX -ElectricDrive
Electro-mechanical Servo-Systems
0,5 – 400 kN Press force
line-Q
line-X

1

TOX -ElectricDrive
®
When work processes require high
flexibility and precision, then con-
ventional drives are often no longer
sufficient. This calls for the use of
electromechanical servo drives.
Tailored drives from 0,5 – 400 kN.
From the standard drive up to
the complex special machine.
Applications for TOX®-Servo-System:
Clinching, Assembling,
TOX®-sheet metal Press-fitting,
joining Mounting
Scope of delivery:
The set:
TOX®-Electric Power Module
or TOX®-Electric Power Curver
Mechanical
Housing with planetary roller spindle
(EPMS 10 with ball screw), working
rod, bearing, resolver, motor with
reducer, DMS force transducers
Controller
Complete control unit, incl. ballast
resistor and Ethernet cable.
2 www.tox-us.com 40.200905.us
Advantages TOX®-ElectricDrive:
• High life expectancy and robust-
ness due to the compact planetary
roller screw spindle
• Future-oriented project planning
and very good retooling capability
due to its universal applicability
• Maximum energy efficiency, i.e.
significantly reduced operating
costs compared to conventional
drives
• Special executions can be easily
realized due to the modular design
• High-dynamic performance by force
and distance regulation and the
possibility of transition speed
Inserting, Riveting, Punching,
Fastener-Insertion Crimping, Piercing
Flaring
TOX®softWare Axis-Controller
(line-X shown)
Cable set
Applicable for use with cable tracks
(pay attention to the minimum ben-
ding radius).
1x Motor cable, 1x resolver cable, 1x
force sensor cable, (standard length
5 m, additional lengths up to 25 m in
steps of 5 m are available). Cables
for robotic applications available also
on request.
l i n e -
X
Q
• High precision due to adaptable,
regulated deflection compensation
• Simple and comprehensive para-
meter setting, control, service, via
TOX®softWare
• Can be run on most commonly
used operating systems
• Utmost safety up to and including
category 4 as per EN 954-1,
Performance level e as per EN ISO
3849-1 and SIL3 as per EN/IEC
62061 is possible
• Stand-alone operation without
PC/PLC is possible
• The system is pre-configured and
calibrated, thus, ready for service
plug and play
Coining, Clamping, Pressing,
Marking, Tensioning, Compressing,
Stamping Peening Bending
Cable set consisting of Ballast
motor cable, resolver cable resistor
and force sensor cable
TOX®softWare on CD-Rom
• no licence fee
• can be updated
• Independent of operating system
• free unlimited use without additional
cost
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X
Q
Network for modern production
Process monitoring, operating, programming and diagnostics directly over your network.

Production Zone controller PC/Laptop or

monitoring IPC for servi-
cing, parameter
Ethernet TOX®softWare setting and PLC controller
visualization
Quality data Production Statistics Logfile
data

Ethernet

Fieldbus e.g. Profibus DP

TOX®-Service:
The decisive advantage
• Dependable service worldwide
(see brochure backside)
• Remote service possible over
modem generally installed in each
complete machine delivered or via
company network (VPN)
• Wide experience in various applica-
tions (general industry, automobile,
medical technology, …)
• TOX® is your active partner during
the entire project duration, from the
planning to the operation stages
• Installation and process optimization
assistance
• Training at the customer or in-house
at TOX®
• Calibration and repair service
• Hotline service
+49 (0) 160 / 96372299
Maintenance:
The electro-mechanical servo
systems are designed such that only
minimal maintenance work is requi-
red.
• Maintenance-free servo motors
• Maintenance-free gears
• Maintenance-free belt drive
(for EPMK-/EPMR-Series)
• Long lubrication intervals for the
spindle

From single components to complete machines

System solutions from one source. See page 22 - 23 for application examples.

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The electromechanical servo spindle X

Q
Design (example: EPMK 55)
Anti-rotation 2 greasing points Housing with plane- Housing with
for spindle (plugged) tary roller spindle belt drive

Eyebolt provision
(both sides)

Working rod

Mounting pilot Bolt circle for Force sensors Resolver Electrical Servo- Gearbox (not
mounting screws (for distance interfaces motor with EPMK 10)
measurement)

Mounting instructions: Referencing:

The working rod should be guided Generally, referencing is done using
externally in order to avoid any the internal positive stop of the servo se
potential side loads. You will find cor- drive. Alternatively, referencing can s, plea
file
t
CAD it us a om
responding examples in the TOX®- be done using an external limit
Presses catalog. The connection to switch. For s .c
vi -u s
the external guidance or ram guide t o x
w.
plate must be done using a flexible ww
coupling. For more information on
our couplings, please see data sheet
10.00 for TOX®-Powerpackage acces-
sories.

Planetary Roller Screw

Advantages: Planetary roller screws are designed The data required or the calculation
• Compact design for high loads over millions of cycles can be found in your offer or at
• High life expectancy making them the best choice. www.tox-de.com.
• High static capacity due to large
bearing area We will be glad to provide a calculati- The calculated life expectancy is a
• Highest transmission speed on of the expected life expectancy if theoretical value with a 90% probabi-
• Highest efficiency you provide us with your cycle load lity.
• Highest rigidity requirements.
• High revolutions

Construction of a Planetary Roller Spindle

Spindle

Planetary roller Spindle nut

4 www.tox-us.com 40.200905.us
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Model Overview
• Press force from 0,5 – 400 kN
X
Q
• can be mounted in all TOX® press frames (see TOX®-Presses catalog)
• can be mounted in any orientation
Electromechanical servo drive with
planetary roller screw:
• High speed
• Highly dynamic
• Precise
• Long lifetime
• Modular design
• Precise force measuring
• Integrated anti-rotation

The slim standard drive Applications:

TOX®-Electric Power Module EPMS • Joining machines
10*, 25, 55, 100, 200 kN • Assembly machines
• Special machines
• Standard design
• Minimum space requirement

The compact drive Applications:

TOX®-Electric Power Module EPMK • Joining machines
10*, 25, 55, 100, 200, 400 kN • Assembly machines
• Special machines
• Compact design • Press drive for presses with the
• Optional brake (see option) highest safety requirements
(see page 2)

The robotic tongs drive Application:

TOX®-Electric Power Module EPMR • Minimum space requirement
55, 100 kN • TOX® robot mounted clinch units
type TZ
• Super compact
• Super light
• With special flanging system

*EPMS/EPMK 10 with ball screw and without gear reducer.

Option:
Holding brake/redundant safety The maximum holding force of the
brake brake is at least 5% of the corre-
The EPMK drive can be additionally sponding nominal force. Technical
equipped with brakes: either with a data and dimensions incl. models
holding brake to avoid a drifting of with stronger brakes on request.
the working piston in case of heavy
tool loads or with a redundant safety
brake to fulfill highest safety require-
ments (see page 2).
How to order:
EPMS 025.030.250.

Stroke [mm]
Variant number
Rated force kN
Design: S = standard/K = compact/
R = robotic tongs drive
Electric Power Module
40.200905.us www.tox-us.com 5
 l i n e -

Data sheet
TOX®-Electric Power Module EPMS 10, 25, 55, 100, 200 kN
X
Q
e
pleas
A D files,
For C isit us at
v com
w .to x-us.
ww
I J
B
U M***
T K***
R G W
C

ØV

ØF
ØH
A
ØD

L
N
A2
A1

Dimensions

Order no. Nomi- Weight

nal approx.
force
Type Stroke [kN] A A1 A2 B C D Ff7 G H I J K L M N R T U Vg6 W kg
EPMS 010.030. 250 10 70 90 76 939 8xM8x16 60 50 10 30 15° 75° 20 M12x1,5 32 24 300 390 720 – – 21
EPMS 025.030. 250 25 70 90 76 1047 8xM8x16 60 50 10 30 15° 75° 28,5 M22x2 48,5 24 300 390 568 18 7 25
EPMS 055.030. 300 55 95 105 105,5 1218 8xM10x20 83 70 10 40 15° 75° 35 M30x2 60 34 316 456 678 26 7 43
EPMS 100.030. 300 100 115 130 122 1373 8xM12x25 98 75 15 50 15° 75° 36 M30x2 61 41 343 483 1316 26 7 72
EPMS 200.030. 300 200 145 – 146 1618 8xM16x25 125 100 18 70 15° 75° 46 M39x2 81 60 385 525 – – – 140

Specifications EPMS 010.030.250 EPMS 025.030.250 EPMS 055.030.300 EPMS 100.030.300 EPMS 200.030.300
Mechanical
Rated force* push 10 kN 25 kN 55 kN 100 kN 200 kN
Rated force pull 3 kN 7,5 kN 16,5 kN 30 kN 60 kN
Stroke** 250 mm 250 mm 300 mm 300 mm 300 mm
Max. speed** 300 mm/s 220 mm/s 200 mm/s 200 mm/s 85 mm/s
Max. short-term 10% of rated force
overload
Positional repeatability < ± 0,01 mm
under load****
Sensors
Load cell 0,5 – 10 kN 1,25 – 25 kN 2,75 – 55 kN 5 – 100 kN 10 – 200 kN
Rated force 10 kN 25 kN 55 kN 100 kN 200 kN
Accuracy < +/- 0,5 % of rated force,pressing
Resolver x x x x x
Resolution 0,0012 mm 0,0004 mm 0,0004 mm 0,0005 mm 0,0003 mm
Electrical
Protection class Motor/drive IP54 (as component)
Mains supply see axis controller
Climatic conditions + 10 to + 40°C, from 40° C performance loss, max. 55° C; air moisture < 75%**, without condensation

*Recommended operating range 5-100%

**Specials on request.(colour, stroke, speed, ..)
***Zero position of drive is the reference (marked) position + 3 mm
****in thermal transient condition

6 www.tox-us.com 40.200905.us
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Data sheet
TOX®-Electric Power Module EPMK 10, 25, 55, 100, 200, 400 kN
X
Q
ase
s, ple
brake AD file
tio n a l with afety For C isit us at
Op 4s v s.com
gory
for ca te
ts w w .tox-u
emen w
requir
A1
A2 B
U M***
T K***
J I R G W

X
ØC
ØY

A
ØV

ØH
ØF
L
ØD
P

Dimensions

Order No. Nomi- Weight

nal approx.
Strok force
Type e [kN] A A1 A2 B C D Ff7 G H I J K L M N P R T U Vg6 W X Y kg
EPMK 010.030. 250 10 70 92 76 657 8xM8x16 60 50 10 30 15° 75° 20 M12x1,5 32 24 211 300 390 568 – – 24 59 22
EPMK 025.030. 250 25 70 92 76 657 8xM8x16 60 50 10 30 15° 75° 28,5 M22x2 48,5 24 211 300 390 568 18 7 24 59 26
EPMK 055.030. 300 55 95 120 105,5 761 8xM10x20 83 70 10 40 15° 75° 35 M30x2 60 34 245 316 456 678 26 7 28 60 46
EPMK 100.030. 300 100 115 156 122 854 8xM12x25 98 75 15 50 15° 75° 36 M30x2 61 41 280 343 483 750 26 7 28 62 78
EPMK 200.030. 300 200 145 170 146 973 8xM16x25 125 100 18 70 15° 75° 46 M39x2 81 60 327,5 385 525 838 – – 52 94 154
EPMK 400.030. 300 ±400 250 276 250 1260 8xM24x40 200 150 20 100 30° 60° 60 M64x2 120 85 525 432 552 1074 – – 60 114 543

Specifications EPMK 010.030.250 EPMK 025.030.250 EPMK 055.030.300 EPMK 100.030.300 EPMK 200.030.300 EPMK 400.030.300*****
Mechanical
Rated force* push 10 kN 25 kN 55 kN 100 kN 200 kN 400 kN
Rated force pull 3 kN 7,5 kN 16,5 kN 30 kN 60 kN 400 kN
Stroke** 250 mm 250 mm 300 mm 300 mm 300 mm 300 mm
Max. speed** 300 mm/s 250 mm/s 200 mm/s 200 mm/s 85 mm/s 40 mm/s
Max. short-term 10% of rated force
overload
Positional repeatability < ± 0,01 mm
under load****
Sensors
Load cell 0,5 – 10 kN 1,25 – 25 kN 2,75 – 55 kN 5 – 100 kN 10 – 200 kN 20 – 400 kN or
-20 – -400 kN
Rated force 10 kN 25 kN 55 kN 100 kN 200 kN 400 kN
Accuracy < +/- 0,5 % of rated force,pressing
Resolver x x x x x x
Resolution 0,0012 mm 0,0004 mm 0,0004 mm 0,0005 mm 0,0003 mm 0,0015 mm
Electrical
Protection class Drive IP54 (as component)
Mains supply see axis controller
Climatic conditions + 10 to + 40°C, from 40° C performance loss, max. 55° C; air moisture < 75%**, without condensation

*Recommended operating range 5-100%

**Specials on request. (colour, stroke, speed, ..)
***Zero position of drive is the reference (marked) position + 3 mm
****in thermal transient condition
*****EPMK 400 only with Rack Controller or with Axis Controller line-X available

40.200905.us www.tox-us.com 7
 l i n e -

Data sheet
TOX®-Electric Power Module EPMR 55, 100 kN A D files, ple
ase X
Q
For C isit us at
v om
.to x-us.c
www

D2 D1

C1

C
2

E1
E2
N

A
C3
C4

B
U
A1 T
A2 R
A3 Q
C M***
K***
X G W
ØY

ØH
ØV

ØJ

F
L
P

F2
F1

F4
F3
Dimensions
Order no. Nomi- Weight
nal approx.
force
Type Stroke [kN] A A1 A2 A3 B C C1 C2 C3H7 C4H7 D1 D2 E1 E2 F F1±0,02 F2 F3 F4 G H J kg
EPMR 055.030. 100 55 95 120 105,5 39 567 27 13 9 14 14 15 21 60 62 92,5 45 62,5 6 9 4 40 28 38
EPMR 100.030. 100 100 115 144 121,5 57 668,5 33 17,5 11 14 14 17 25 85 84 115,5 58 75,5 6 10 4 50 33 68

Order no.
Type Stroke K L M N P Q R T U Vg6 W X Y
EPMR 055.030. 100 18 M24x1,5 37 24 245 83 182 262 484 22 6 28 60
EPMR 100.030. 100 17 M24x1,5 36 30 274 120 218 298 565 22 6 28 62

Specifications EPMR 055.030.100 EPMR 100.030.100 The tightly toleranced (H7) keyways
Mechanical on the mounting flange provide for
Rated force* push 55 kN 100 kN precise alignment of the drive with
Rated force pull 16,5 kN 30 kN respect to the direction of travel.
Stroke** 100 mm 100 mm The height and position of the drive
Max. speed** 120 mm/s 120 mm/s can be precisely adjusted using
Max. short-term overload 10% of rated force spacer plates and keys.
Positional repeatability under < ± 0,01 mm
load****
Sensors
Load cell 2,75 – 55 kN 5 – 100 kN
Rated force 55 kN 100 kN
Accuracy < +/- 0,5 % of rated force,pressing
Resolver x x
Resolution 0,00025 mm 0,0003 mm
Electrical
Protection class Drive IP54 (as component)
Mains supply see axis controller
Climatic conditions + 10 to + 40°C, from 40° C performance loss, max. 55° C;
air moisture < 75%**, without condensation

*Recommended operating range 5-100%

**Specials on request. (colour, stroke, speed, ..)
***Zero position of drive is the reference (marked) position + 3 mm
****in thermal transient condition

8 www.tox-us.com 40.200905.us
 l i n e -

The Servo Spindle in operation X

Q
Robot guided clinching tongs
EPMR 55 used in TOX®-Robotic tongs TZ for joining sheet metal

EPMR 55

Application:
Option:
Metal joining with
Terminal box for starting the
TOX®-Round Joint
compensating slide and the
(see brochure: TOX®-
spray lubrication equipment, and
Joining Systems)
manual initiation for spraying a
lubricant on to the joining area, if
required.

TOX®-Robot tongs TZ Option:

(see brochure: TOX®-Tongs) Robot coupling

TOX®-Electric PowerKurver EPC 90 kN

Servo-Drive-Unit with planetary roller Applications:

screw in combination with our proven • Clinching
TOX®-PowerKurver cam activated • Clamping
press design. The large opening • Marking
angle allows for easy access to too- • Robot Applications
ling.
Advantages:
• Self-locking • Part accessibility
• Long lifetime • Top loading
• Freely programmable opening • Clamping and Clinching at the
angles, up to 90°. same time

Ordering example:
EPC 90.090.000
Version number
Opening angle
Press force (kN)
Electric Power Curver
Accessories such as for TOX®-
PowerKurver type KK are possible
(see TOX®-PowerKurver catalog).

40.200905.us www.tox-us.com 9
 X
l i n e -

The line-Q and line-X idea X

Q
Q
Between the servo drive and the servicing, parameter setting and visualization, there is always an axis-controller.
The functions and interfaces available depend on the type of the axis-controller.

Option:
Ethernet 24 V DC brake

PC/Laptop or IPC Servo motor

for operating and
process monitoring
Fieldbus Resolver signal
I/O

Load cell signal

Control for parameter setting
and commissioning
For the TOX®-ElectricDrive, one may
select between two single axis con-
trollers, line-Q or line-X. Both lines
are identical in their mechanical
design and differ only with regards to
the number of features.
Axis-Controller (Ill.: line-X)
Complete program line-Q
• Short lead time
• Limited in the number of functions
and customer interfaces
The first choice if the extensive
list of functions is sufficient.
Spindle (Ill.: EPMK)
Complete program line-X
• Nearly unlimited number of
functions with custom interfaces
possible.
The best choice if the extensive
list of functions is already suffi-
cient or can be expanded by the
TOX® service experts.

TOX®softWare

NETWORK Ethernet
Interbus/ServiceNet/Profibus
RS 232/485
PLC

l i n e - l i n e -
TOX®-Axis-Controller TOX®-Axis-Controller
line-Q Q line-X X
Standard Standard
Data bus • RS 232 / RS 485 Data bus • Ethernet TCP/IP
• Ethernet TCP / IP Fieldbus • Profibus-DP
Fieldbus • Profibus-DP • CanOPEN

Optional Optional
Interbus instead of Profibus Other Fieldbus available over
Gateway, e.g. Interbus, DeviceNet,
Other Fieldbus available over ControlNet, Ethernet IP
Gateway, e.g. DeviceNet,
ControlNet, Ethernet IP

Analog Analog
0-10 V, alternative to Profibus 0-10 V; two available with one free

Digital Digital
8 inputs / 8 outputs 8 inputs / 4 outputs
expandable to 32 expandable to 255

10 www.tox-us.com 40.200905.us

TOX -Axis-Controller line-Q and line-X
®
TOX®-Axis-Controller:
the central intelligence
Both freely programmable axis con-
trollers are single axis controllers with
integrated logic and servo amplifier.
They control and monitor all functions
of the TOX®-ElectricDrive system.
Advantages include the highly dyna-
mic processing of pressing programs
and fast reaction to variations in the
process. During and after production,
the process data can be taken from
the controller for further processing or
documentation.
Configuration and Programming
with the TOX®softWare
All parameters, configuration and pro-
gram functions residing inside the
controller will be accessed with the
software module TOX®-Worx in the
software package TOX®softWare. The
TOX®softWare is delivered with each
TOX®-ElectricDrive. The following
system requirements are necessary
to access the TOX®softWare in the axis
controller:
TOX®softWare in the axis controller:
• (Industrial) PC (Pentium III)
• Operating system WIN2000 or
higher
• Java Runtime
The circuit diagrams are included
with the operating manuals. On
request, we can provide an info CD
including wiring examples,
TOX®softWare, PLC building blocks
and the operating manual immediate-
ly after receipt of the order.
Common Characteristics:
• Faster commissioning,
Plug and Work
• Extensive programming and
diagnostic functions
• Parameter programming of
processes (online and offline)
• Pre-configured and pre-calibrated
• Maintenance-free
• Display and monitoring of force-
travel progressions
• Graphical process analysis
• Display of process results including
status, date and time stamp
• Target position with monitoring of
force limits
• Target force with monitoring of
position limits
• Window monitoring
• Sequential control
• Run according to PLC standard
values
• PLC function blocks e.g.
Siemens S7
• Deflection compensation
• Abstract from the standard function
library:
- Force and/or travel controlled
commands
- Functions for process control and
process data recording
- Graphical displays
l i n e -
X
Q
- Processing of input signals as well
as definition and setting of output
signals
- Taring and continuous monitoring
of force sensors
• Quality data management over
Ethernet and Fieldbus
• Commissioning function without
PLC
• Input and allocation of calibration
values of the force sensors
• Integration of external force sensors
(DMS and 0-10 V are possible)
• Functional test of load cells
• Highest safety category possible
(see page 2)
• Axis controller and ballast resistor
can be installed in any applicable
standard enclosure
• Electric connections are provided
with plugs
• Integrated overload functions for
motor and servo amplifier
• Electrical isolation between
controller and amplifier
• 3-cable technology
• Protection degree IP20, can be
extended to IP54
• Compact design with direct AC
supply and integrated resolver and
motor connection
• For spindle operation, including
process monitoring a PC is not
required
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TOX -Axis-Controller line-Q

®
Q

X30 AC Input X31 Ballast resistor

Status displays LED X40 Category 3 safety

X2-com-Terminal
X50/X51 Digital
Programming port
Input/Output

X13/X14 Active/passive
Status displays
transducer
LED I/O

X6 I/O Expansion
COM 2/3 RS 232
X4/X5 Encoder input (e.g. barcode input)

X3 Encoder output
X10 Profibus/Interbus

X1 Servo
feedback X7 Ethernet

X20 Motor plug

Special properties of line-Q

• Stores last 1000 process data sets
• Memory for about 25 processes
Special solutions
(for TOX® standard workflows)
• Digital force regulation with
0.5 ms sample rate of 0,5 ms Complete panel in IP54.
• Four controllers are allocated Customer specific solutions
according to spindle sizes and are possible on request.
specially matched to their capacity
ranges
• Customized interfaces are possible
within a limited scope

General data and installation requirements

Operating conditions
Circuit type with grounded star-circuit unlimited use
IT-net Follow instructions for special measures!
Standards
Conformity CE Low voltage directive (73/23/EWG)
Approvals UL 508C Power Conversion Equipment (File-No. 32659)
Enclosure
Enclosure type IP20 not in the connecting area of the
Contact protection motor side connectors.
according to type 1
Climatic conditions
Operation* IEC/EN 60721-3-3 3K3 (+5 ... +40°C)
Derating of rated output current +40 ... +60°C: 1,5%/°C
air moisture max. 95%, without condensation
*Attention: In case of an installation at 1000 m above sea level the reduction of the nominal current will be 15%/1000 m.

12 www.tox-us.com 40.200905.us
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TOX -Single Axis Controller line-Q

®
Q

125,6 273,5
118 206,5
55,5
7

2,5
10,5

243,9
277,4
285
310,8
7 53,25

Easy installation due to - Standard industrial power input: Standard interfaces

compact cabinet design
The TOX®-Axis-Controller has been
designed for optimized integration.
3 x 480 V (+5% ; -25%) = • Ethernet
360 ... 504 V AC 50/60 Hz • Profibus or Interbus
- Dimensions of controller W/H/D: • RS 232
273.5/310.8/ 125.6 mm • RS 485
- Dimensions of ballast resistor
W/H/D: 30/60/355 mm
- Built-in depth of switch cabinet:
300 mm

Block diagram
Use of the TOX®-ElectricDrive System
Simplified presentation.

line-Q
+ UB RS 232 programming
Ballast process data
X31 X2
resistor PC
Rext
Ethernet, programming,
Standard Interface, Profibus process data
X10 X7

Optional interface, Interbus

X11/X12 X13 Force sensor
Emergency switch button
light grille/protective door
Resolver Servo
delayed X1
drive
to category 3 X50-52
switching-off X40 I/O X20 Motor

Emer- undelayed Control, digital, PLC

gency
switch Emergency switch box with a Green: Scope of delivery TOX®-
delay of approx. 150 – 500 ms. ElectricDrive Set
as per risk analysis and after- Red: supplied by customer
running test
Ordering description: EDC2
See offer or order confirmation for
precise description.
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TOX -Axis-Controller line-X

®
X

Pluggable Axis controller Pluggable modules Pluggable I/O connections

Basic appliance
Mains
connection
CANonBOARD

Analog Inputs/
Profibus Outputs
module
Digital I/O
Ethernet
TCP/IP module

Mains filter Memory

module Diagnostic
Mounting socket interface
Safety module

Motor Resolver-
Axis controller
connection connection

By plugging the axis-controller to or The plug-in system of the modules

off the mounting base, it can be makes them easy to select and to
quickly connected or replaced. change:
• Safety
• Bus (communication)
• Intelligence

Special properties of line-X

• Storage of the last 500 process data
records
• Digital force regulation with
sampling rate of 1ms
• Memory for about 270 processes
(for TOX® standard workflows)
• Six controllers are allocated
according to spindle sizes and are
specially matched to their capacity
ranges
• Customized interfaces are generally
possible

Special solutions

Complete panel in IP54.

Customer specific solutions pos-
sible on request.

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 l i n e -

Functions and possibilites of line-X X

Exclusive properties of line-X
• Integrated PLC functionality,
IEC 61131
• Envelope curve monitoring
• Controlling remaining bottom
thickness for clinching (quality
dimension X)
• Integration of external distance
sensorics
• All modules are pluggable
• Customized fault diagnostics are
possible
• Customized functions are possible
Current volume of special function
library
Process jumps: process calling, sub-
process calling
• With process jumps it is possible to
define jumps into other processes
during and/or at the end of a
process.
Spindle data
• By adding this function, you can
change the spindle data “on the fly”
while the process is running. At the
end of the process, the spindle data
will be reset to the default value.
This gives you the possibility to
work with additional force sensors
on one spindle.
Stopping the process
• By adding this function, the process
is stopped. This is useful in combi-
nation with the “conditional check”
function.
Conditional check function (start-,
target-, end condition)
• Based on a selectable source (IO,
Fieldbus, variable). This function
gives you the possibility to define
multiple conditional targets within a
process.
Set and evaluate integer and/or real
variables
• This function is used to define an
integer and/or real variable for the
“conditional check” function.

General data and installation requirements

Operating conditions
Circuit type with grounded star-circuit unlimited use
IT-net Follow instructions for special measures!
Standards
Conformity CE Low voltage directive (73/23/EWG)
Approvals UL 508C Power Conversion Equipment (File-No. 32659)
Enclosure
Enclosure type EN 60529 IP20 not in the connecting area of the
NEMA 250 Contact protection motor side connectors.
according to type 1
Climatic conditions
Operation* IEC/EN 60721-3-3 EN 50178 3K3 (-10 ... +55°C)
Derating of rated output current +45 ... +55°C: 2,5%/°C
air moisture max. 85%, without condensation
*Attention: In case of an installation at 1000 m above sea level the reduction of the nominal current will be 15%/1000 m.
40.200905.us www.tox-us.com 15
 l i n e -

TOX -Axis-Controller line-X

®
X

Mounting dimensions Mounting plate Mains filter for EPM x 10-100

15 60

Size of the TOX®-Electric Dimensions a Weight Size of Wei-

Power Module (mm) (kg) the TOX®- Dimensions (mm) ght
Electric (kg)
EPMx 010 90 5,3
Power
EPMx 025 Module a b b1 b2 e c1 d g m
EPMx 055 120 8,1 EPMx 200
EPMx 100 206 606 556 630 294 170 585 6,5 12,5 26,5
EPMx 400

- Standard industrial power input: 3 x 180 - 550 V (+0% ; -0), Nominal power at 400 V AC 50/60 Hz
- Dimensions of ballast resistor W/H/D: 30/60/355 mm
- Built-in depth of switch cabinet: 400 mm

Blocks diagram
Use of the TOX®-ElectricDrive-System.
Simplified diagram. line-X

Ballast
X105 MMI
resistor
Ethernet, programming, PC
process data
MXI2
Standard Interface, Profibus
MXI1

Emergency switch button

Force sensor
light grille/protective door X3
approx. 150- Servo
500 ms Resolver
X7 drive
delay
Safety X4, X5
Motor
category 3 MSI X105
I/O

Emerg undelayed Control, digital, PLC

ency
switch Emergency switch box with a green: Scope of delivery TOX®-
delay of approx. 150 – 500 ms ElectricDrive Set
as per risk analysis and after- red: supplied by customer
running test
16 www.tox-us.com 40.200905.us
 l i n e -

TOX

®
softWare Facts and Features for line-Q and line-X
User friendly
 Easy configuration
 Integrated documentation
 Designed for touch screen use
The TOX®softWare consists of the pro-
grams: Server (connection from the
PC to the axis controller), Worx and
HMI.
 Platform independent
X
Q
 Supports all common interfaces
 Several user levels
TOX®softWare is a new, interactive The user will be able to quickly define
Software Suite with completely inte- and configure new projects without
grated controls and monitoring functi- the knowledge of any programming
ons specifically designed for all appli- language. Operating interface and
cations. software are programmed by TOX®
and may be adapted in conformity
with customer’s request.

TOX®softWare Worx
Project environment
The Worx-Module has pre-configu- Worx-Project management line-X
red, ready to use press function
blocks which can be customized to
the individual application. A dialog
based project-wizard will aid in the
initial setup and assist in the project
layout. Projects can be saved and
copied as templates for future use.

The Windows based user interface

has a familiar look and feel enabling
quick and easy navigation through
the projects. The Explorer-style menu
layout supports easy administration Abstract from the function library line-X
of press programs and file handling.

Programming
The process cycle is configured by
selecting process specific function
blocks from a menu, building a press
sequence. No CNC code program-
ming knowledge is required.

Click on the Menu function block

Enter the required parameters
Start the process Worx Diagram line-X
Control the process

Commissioning
An online mode enables the user to
monitor all controller functions and
I/O in real time for commissioning
and troubleshooting purposes.

Curve mapping
I/O Display
Jog function

40.200905.us www.tox-us.com 17
 TOX®softWare HMI

HMI-communication environment Manual operation picture line-Q

(HMI = Human-Machine-Interface)
The TOX®softWare HMI is used by the operator to
control and visualize the process. The user platform
can be adapted by the user. It is also possible to
configure a data export in this part of the software.

• Adaptable screen surface

• Messages can be freely defined
(errors, information, status, etc.)
• Manual / Automatic screen
• Diagnostic screen with logbook
• Process data export in Excel-compatible CSV TTM (TOX® Touch Menue) line-Q
format for quality management
• Counter (total, IO ,NIO, maintenance intervals)
• Protected against unlicensed change access by
authorization
• Special screens with additional information can be
integrated (e.g. temperature indicators, travel
measuring systems and the like)
• Backup of all parameters by pressing a button

Diagnostic module line-Q

18 www.tox-us.com 40.200905.us
TOX®softWare HMI with line-Q

Process control using the window technique Graphics module line-Q

Monitoring of a force/travel progression of

a process with defined windows.

+ An almost unlimited number of force/travel

windows can be defined.

Sequential control – expanded process admini- Sequence module line-Q

stration and simplified conversion scenario

+ Piecepart-specific parameter change by pressing

a button and selection of another sequence
+ Maximum number of processes limited only by the
hard drive capacity
+ Dynamically controlled process flow with IO/NIO
statement
+ Highly efficient manual workplaces thru single
cycle control possibility

Process data export in graphics module line-Q

40.200905.us www.tox-us.com 19
 l i n e -

TOX ®
soft Ware HMI with line-X X

Monitoring Clinching module with envelope curve line-X

The TOX®softWare HMI collects the complete
force/travel diagrams and evaluates them with the
help of freely programmable windows and/or envelo-
pe curves. The values can be zoomed and displayed
in different ways. SPC Data can be archived (SPC:
statistic process control).

Simple teach-in mode

+ Automatic teaching of the processes and the force
limits in the target window and the envelope
+ no programming, just parameter setting
+ automatic scaling of diagrams

Process monitoring using envelope curves

The envelope curve determines by two limit curves Clinching module process parameter line-X
the path of the force/travel progression
+ Full monitoring within the set point and target
windows, i.e. the force/travel characteristics curve
can not fall outside the upper and lower limits
+ Selection possibility!
For curves deviating from the envelope, these
options apply:
process will continue until target
window is reached
stop process

Clinch module for the modern sheet metal

joining technology
Precise control of the quality dimension X (remai-
ning bottom thickness after the clinching process) in
consideration of the machine deflection.
Irregularities in production (fluctuations in sheet metal
thickness, fluctuations in surface condition ...) could Control
otherwise cause fluctuations of the dimension X. Punch side
e
dimension "X"

Die side

+ active stabilization of variances Point diameter

technical optimum achieved with an accuracy of
± 0,04 mm
+ the X dimension is assured independent of
material combination and properties
Pressing module process parameter line-X

Pressing module for highly flexible pressing

procedures
+ Cockpit function due to complete parameter setting
on one screen
+ High precision possible, for example, by the
integration of different piecepart specific deflection
values in the process flow
+ High repetitive accuracy, for example, by the
possible compensation of dimensional fluctuations
of piecepart lengths
+ Complex process flows can be realized
(several jump function, sub-process calling etc.)

20 www.tox-us.com 40.200905.us
 l i n e -

Control Options for line-Q and line-X X

IP54 enclosure
For axis controller package, including
fan or cooling unit. Specifications
according to TOX® Standards. Special
executions available on request
(Example see picture page 12 and
14).
Safety Controls
All the following control variants are
type-examination tested.
Basic Controls:
• Cycle initiation over 2-hand buttons.
Both switches must be held down
during the complete cycle.
• Visualization over IPC with swivel
arm to be mounted on pressframe
with flange selectively from above
or below.
Options to Basic Controls:
• Function safe return stroke.
The return stroke of a press takes
place automatically after completing
the press cycle. The switches do not
have to be held down during the
return stroke.
• Function safe speed. The drive
extends with a maximum speed of
10 mm/s. The controls can be
activated with a 1-hand switch or
foot switch.
Control with protective door:
• Cycle initiation by 1-hand switch or
foot switch
• The pressing process is only started
if the protective door is closed
Q
Light Curtain Controls:
• Safety guarding and controlling
version
Two operating modes are available:
1. The light curtain has no control-
ling function. Cycle initiation over
1-hand switch or foot switch.
2. The light curtain has a controlling
function. Cycle initiation after end
of light curtain interruption
(so-called Talot control)
Special executions (on request):
• Software integration of external
components, e.g. sensors for
temperature, travel, etc.
• Activation of additional motions, e.g.
for a sliding table, a guarding door,
etc.

Industrial PC from TOX®:

the sturdy alternative to usual PC systems

Execution IPC built in version

Touchscreen 17 inch TFT colour display

Dimension W: 482,6 mm
front panel H: 354,8 mm
Operating system Windows XP
Software TOX®softWare
Working memory 1 GB DDR-RAM
Processor 1,5 GHz
Mass storage 60 GB HD
Interfaces 4x USB (two front connection)
2 x Ethernet
2x RS232
Protection class IP 65 frontside, IP 20 backside
Ambient temperature +5°C...+45°C
Power supply 24 V

Options:
- Panel IP 65, with interface for a
swivel arm (CP-L)
- Keypad
Keypad holder

40.200905.us www.tox-us.com 21
 l i n e -

X
Q
Accessories
Grease gun for re-greasing the TOX®-ElectricDrive Systems

It is a must for the reliable operation Greasing intervals and amount

of the spindle. according to the manual,
Order no.: ZFP suitable for 400g TOX®-Spindle
grease cartridge.

400g TOX®-Special grease

cartridge
Order no.: ZFE

Automatic lubrication for Possible on request.

TOX®-ElectricPower Module

Calibration equipment type ZKE

For the re-calibration of the TOX®-
ElectricPower Module. The interval
for the re-calibration is fixed by cus-
tomer’s quality management.
Includes:
- Precision force sensor
10, 50, 100 or 200 kN
- Digital display unit
- Shockproof power cord
- Calibration certificate
- Aluminum case

Applications
From the TOX building blocks to special machines

Planning and design of complete

presses and special machines.

TOX® PRESSOTECHNIK helps you

solve your production demands with
the application of specific solutions
made with components from our
standard product line.

Realization of electro-mechanic pres-

ses of utmost safety level (see page
2) and tested by the German
Employer’s Liability Insurance
Association.

TOX®-Press series PC
With 2-column ram guide, EPMK
100 with brake, protective hood with
exhaust fan, safety 2-hand controls,
function “safe direction” with opera-
tor guarding and touch screen IPC
with TOX®softWare
see picture page 3

22 www.tox-us.com 40.200905.us

Applications
TOX®-Press series PC
With 2-column ram guide, for
pressing and pulling operation,
EPMK 400 with brake, protective
hood with exhaust fan, safety
controls with function “safe
speed”, stroke initiation via
1-hand key or foot pedal
TOX®-Automatic station
series CMB
With linear guided ram mounted
in the C-frame, UUM table,
EPMK 100, control for automatic
operation with touch screen IPC
with TOX®softWare
TOX®-Automatic station
C-frame type CEJ with CER
stand, EPMR 55, TOX®-Clinching
tools and TOX® lube spray
equipment
TOX®-Press series MAG
With 4-column ram guide,
EPMK 100 with holding brake,
slide table with locking cylinder,
UUM of welded construction,
safety control with protective
door and 1-hand key or foot
pedal, with touch screen IPC
with TOX®softWare
l i n e -
X
Q
TOX®-Press series MB
with 2-column ram guide, base
UUM, EPMK 55 with brake, safety
control with protective door and
1-hand key with function “safe
speed” for inching operation with
open protective door and
TOX®softWare
TOX®-Automatic station
C-frame type CEB with CER stand,
EPMK 55 positioning cylinder for
CEB, EPMK 55 for pressing and
pulling operation, EPMK 10 pre-
load axis with external force sensor
40.200905.us www.tox-us.com 23
 Product Range

TOX®-Powerpackage

TOX®-PowerKurver

TOX®-ElectricDrive

Our Worldwide Sales and Service Network

TOX®-FinePress

TOX®-Presses

TOX®-Controls,
TOX®-Monitoring

TOX®-Joining
Systems

TOX®-Tongs

TOX®-Punching
TOX®-Coining

TOX® PRESSOTECHNIK GMBH &

CO. KG TOX® PRESSOTECHNIK L.L.C.
Riedstraße 4 4250 Weaver Parkway TOX®-Press-Fitting
D-88250 Weingarten Warrenville, IL 60555
Tel. +49 (0) 7 51 / 50 07-0 Tel. (6 30) 3 93-03 00
Fax +49 (0) 7 51 / 5 23 91 Fax (6 30) 3 93-68 00
E-Mail: info@tox-de.com E-Mail: info@tox-us.com TOX®-Production
www.tox-de.com www.tox-us.com
Systems

40.200905.us Subject to technical alterations.